Electrical power connector

ABSTRACT

A printed circuit board electrical power contact for connecting a daughter printed circuit hoard to a mating contact on another electrical component. The power contact includes a main section; at least one daughter board electrical contact section extending from the main section; and at least one mating connector contact section extending from the main section. The mating connector contact section includes at least three forward projecting beams. A first one of the beams extends outward in a first direction as the first beam extends forward from the main section and has a contact surface facing the first direction. Two second ones of the beams are located on opposite sides of the first beam and extend outward in a second opposite direction as the second beams extend forward from the main section. The second beams have contact surfaces facing the second direction.

CROSS REFERENCE TO RELATED APPLICATION

This is a divisional patent application of co-pending U.S. patentapplication Ser. No. 10/969,166 filed Oct. 17, 2004, now U.S. Pat. No.7,065,871, which is a divisional patent application of U.S. patentapplication Ser. No. 10/155,819 filed May 23, 2002, now U.S. Pat. No.6,814,590.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to electrical connectors and, moreparticularly, to electrical power connectors used to supply power to aprinted circuit board.

2. Brief Description of Prior Developments

FCI USA, Inc. manufactures and sells printed circuit board power andsignal connectors known as PwrBlade™ in a connection system. An exampleof the PwrBlade™ connector can be seen in U.S. Pat. No. 6,319,075. FCIUSA, Inc. also manufactures and sells high-speed signal connectors knownas Metral™. There is a desire to provide a printed circuit board powerconnector which can be stacked alongside a Metral™ connector, or asimilar connector, such as the connector shown in U.S. Pat. No.5,286,212 or a Future-Bus™ connector.

There is also a desire to increase amperage density of printed circuitboard power connectors. For example, there is a desire to increaseamperage density to about 60 amps per half inch in a card-to-back panelinterface. Connector specifications for secondary circuits incard-to-back panel interfaces, such as standards for clearance andcreepage for a given Voltage, also exist such as in UL 60950, IEC 61984and IEC 664-1. There is a desire to provide a printed circuit boardpower connector system which can meet these standards for higher voltageconnections, such as 150 volts or more for example.

SUMMARY OF THE INVENTION

In accordance with one aspect of the present invention, a printedcircuit board electrical power contact for connecting a daughter printedcircuit board to a mating contact on another electrical component isprovided. The power contact includes a main section; at least onedaughter board electrical contact section extending from the mainsection; and at least one mating connector contact section extendingfrom the main section. The mating connector contact section includes atleast three forward projecting beams. A first one of the beams extendsoutward in a first direction as the first beam extends forward from themain section and has a contact surface facing the first direction. Twosecond ones of the beams are located on opposite sides of the first beamand extend outward in a second opposite direction as the second beamsextend forward from the main section. The second beams have contactsurfaces facing the second direction. These second beams are preferablyone half the width of the first beam so overall normal force is equal ineach direction.

In accordance with another aspect of the present invention, a system forconnecting a daughter printed circuit board to a mother printed circuitboard is provided. The system comprises a first power connector adaptedto be mounted to the mother printed circuit board. The first powerconnector has a first housing and first power contacts. The systemcomprises a second power connector adapted to be mounted to the daughterprinted circuit board. The second power connector has second powercontacts with substantially flat main sections and outwardly bentcontact beams having outward facing contact areas. The second powercontacts are adapted to be inserted into the first housing. The systemcomprises a first signal connector adapted to be mounted to the motherprinted circuit board. The first signal connector comprises male signalcontacts. The system comprises a second signal connector adapted to bemounted to the daughter printed circuit board. The second signalconnector comprises female signal contacts adapted to receive the malesignal contacts therein.

In accordance with one method of the present invention, a method ofmanufacturing electrical power connectors is provided comprisingmanufacturing a first type of electrical power terminal from a metalstock material by use of a metal stamping die; inserting an inserttooling punch into the metal stamping die; stamping a second electricalpower terminal and a third electrical power terminal substantiallysimultaneously from the metal stock material when the insert toolingpunch is located in the metal stamping die; inserting the first type ofelectrical power terminal into a first housing to form a first type ofelectrical power connector, and inserting the second and third types ofelectrical power terminals into a second housing to form a second typeof electrical power connector. The metal stamping die, and optionalinsertion of the insert tooling punch into the metal stamping die, canbe used to form the three different electrical power terminals andsubsequently form the two different types of electrical powerconnectors.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing aspects and other features of the present invention areexplained in the following description, taken in connection with theaccompanying drawings, wherein:

FIG. 1 is a perspective view of a connector system incorporatingfeatures of the present invention and portions of a daughter printedcircuit board and a mother printed circuit board;

FIG. 2 is a perspective view of the connector system shown in FIG. 1from an opposite angle;

FIG. 3 is a perspective view of the first type of power electricalconnector shown in FIG. 1;

FIG. 4 is a perspective view of the first type of power electricalconnector shown in FIG. 3 taken from an opposite angle;

FIG. 5 is a perspective view of a first type of the electrical powercontact used in the connector shown in FIG. 3;

FIG. 6 is a perspective view of the second type of power electricalconnector shown in FIG. 1;

FIG. 7 is a perspective view of the second type of power connector shownin FIG. 6 taken from a generally opposite angle;

FIG. 8 is a perspective view of a second type of electrical powercontact used in the connector shown in FIG. 6;

FIG. 9 is a perspective view of a third type of electrical power contactused in the connector shown in FIG. 6;

FIG. 10 is a front and top side perspective view of one of the powerelectrical connectors attached to the mother board shown in FIG. 1;

FIG. 11 is a rear and top side perspective view of the power electricalconnector shown in FIG. 10;

FIG. 12 is a perspective view of one of the power contacts used in thepower electrical connector shown in FIG. 10;

FIG. 13A is a perspective view of two of the first type of contactsformed from metal stock material on a carry strip;

FIG. 13B is a perspective view of two pairs of the second and thirdtypes of contacts formed from metal stock material on a carry stripformed with a same metal stamping die as used to form the first type ofcontacts shown in FIG. 13A and with use of an additional, optionalinsert tooling punch;

FIG. 14 is a method flow chart of one method of the present invention;and

FIG. 15 is a method flow chart of another method of the presentinvention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring to FIGS. 1 and 2, there are shown perspective views of aconnection system 10 incorporating features of the present invention forremovably connecting a daughter printed circuit board 12 to a back panelor mother printed circuit board 14. In alternate embodiments, featuresof the present invention could be used to connect the daughter printedcircuit board to any suitable type of electrical component. Although thepresent invention will be described with reference to the exemplaryembodiments shown in the drawings, it should be understood that thepresent invention can be embodied in many alternate forms ofembodiments. In addition, any suitable size, shape or type of elementsor materials could be used.

The connection system 10 generally comprises a daughter board connectionsection 16 and a mother board connection section 18. The daughter boardconnection section 16 generally comprises a signal connector 20, a firstpower connector 22, and a second power connector 24. In the embodimentshown, the three connectors 20, 22, 24 are shown stacked adjacent eachother with the signal connector 20 located between the two powerconnectors 22, 24.

The signal connector 20 generally comprises a housing with a pluralityof female signal contacts and possibly ground contacts therein. In apreferred embodiment, the signal connector 20 comprises a Metral™receptacle connector manufactured and sold by FCI USA, Inc.

The present invention relates to a high power connector system forpower-to-daughter card applications. For example, the system can be usedto supply 150 Volts or more. Three power connectors will be describedbelow; namely, a 1×2 right angle header, a 2×2 right angle header, and a2×2 vertical receptacle that will work with both headers.

One of the features of the present invention is the ability to stack thepower connectors adjacent to the signal connectors and the modularity ofthe connector system. For example, a connection section could beprovided with two of the first type of connectors 22 located on oppositesides of the signal connector 20 or, with two of the second type ofconnectors 24 located on opposite sides of the signal connector 20. Thepresent invention also allows a single type of mother board powerconnector 142 to be used which can be connected to either the first typeof connector 22 or the second type of connector 24.

Another feature of the present invention is the increased amperagedensity which can be provided by the power connectors. For example, thesecond type of connector 24 can provide for 15 amps of current percontact for a total of 60 amps per connector. The bottom side of theconnector 24 can be as small as a half-inch, for example, such that theamperage density can be provided at about 60 amps per half inch. Thisincreased amperage density, relative to conventional designs, can beprovided due to the higher conductivity of the high performance copperalloy and, due to the increased air flow through the connector housings26, 74, 144 (see FIGS. 4, 7 and 10).

Another feature of the present invention is the ability for the powerconnectors to meet specification standards for a given voltage forsecondary circuit power card-to-back panel interfaces. Morespecifically, it has been found that implementation of the presentinvention can meet the specifications for UL 60950, IEC 61984 and IEC664-1 for a 150-160 Volt secondary circuit power card-to-back panelconnection.

Referring also to FIGS. 3-5, the first power connector 22 generallycomprises a housing 26 and two electrical power contacts or terminals28. The housing 26 is preferably comprised of a molded plastic orpolymer material. The housing 26 generally comprises a rear section 30and a front section 32. The rear section 30 generally comprises contactmounting areas 34 formed along air flow passages 36. In the embodimentshown, the air flow passages 36 form a majority of a cross sectionalsize of the rear section 30.

The air flow passages 36 comprise holes through a top side 38 and a rearside 40 and bottom side of the rear section 30. The bottom side of therear section 30 includes mounting posts 42 for mounting the housing onthe daughter printed circuit board 12. However, in alternateembodiments, any suitable means for mounting the housing 26 on thedaughter printed circuit board could be provided.

The front section 32 generally comprises a mating connector receivingarea 44, air passage holes 46, 48 at top and bottom sides of the frontsection, and mating connector aligner receiving grooves 50. The matingconnector receiving area 44 is sized and shaped to receive a portion ofa mating connector of the mother board connection section 18. The matingconnector aligner receiving grooves 50, in the embodiment shown, arelocated on a top side and two lateral sides of the front section 32. Theair passage holes 46, 48 are provided to allow air to flow into and outof the mating connector receiving area 44.

The power contacts 28, in the embodiment shown, are identical to eachother. However, in alternate embodiments, the power contacts could bedifferent from one another. The embodiment shown comprises two of thepower contacts 28. In alternate embodiments the power connector couldcomprise more than two power contacts. As seen best in FIG. 5, eachpower contact 28 generally comprises a main section 52, daughter boardelectrical contact sections 54, and mating connector contact sections56. The power contact 28 comprises two of the mating connector contactsections 56. However, in alternate embodiments, the power contact 28could comprise more or less than two of the mating connector contactsections.

The power contact 28 is preferably comprised of a one-piece metal memberwhich has been stamped and subsequently plated; at least at some of itscontact surfaces. The power contact 28 is substantially flat except atthe mating connector contact sections 56. In the embodiment shown, thedaughter board electrical contact sections 54 comprise a plurality ofthrough-hole contact tails. However, in alternate embodiments, anysuitable type of daughter board electrical contact sections could beprovided.

The main section 52 comprises a first retention section 66 located at arear end of the main section and a second retention section 68 extendingfrom a bottom side of the main section. The retention sections 66, 68engage with the housing 26 to fixedly hold the main section 52 in thehousing. However, in alternate embodiments, any suitable system forretaining the power contacts with the housing could be provided. Themain section 52 comprises a recess 70 at the first retention section 66.A crossbar 72 at the rear end of the housing 26 is received in therecess 70. In the embodiment shown, the contacts 28 are loaded into thehousing 26 through the front end of the housing; through the matingconnector receiving area 44.

The mating connector contact sections 56 are substantially identical toeach other. However, in alternate embodiments, the mating connectorcontact sections could be different from each other. Each matingconnector contact section 56 generally comprises three forwardprojecting cantilevered beams; a first beam 58 and two second beams 60.However, in alternate embodiments, the mating connector contact sectioncould comprise more or less than three cantilevered contact beams.

The first beam 58 extends outward in a first direction as the first beamextends forward from the main section 52. The first beam 58 has acontact surface 62 facing outward in the first direction. The secondbeams 60 are located on opposite top and bottom sides of the first beam58. The second beams 60 extend outward in a second opposite direction asthe second beams extend forward from the main section 52. The secondbeams 60 have contact surfaces 64 facing outward in the seconddirection.

The beams 58, 60 are bent outward about 15 degrees from a central plainof the power contact. However, in alternate embodiments, any suitableangle could be provided. In the embodiment shown, the front ends of thebeams 58, 60 are curved inward and also comprise coined surfaces ontheir outer contact surfaces 62, 64. When the power contacts areinserted into the housing 26, the mating connector contact sections 56are located in the mating connector receiving area 44.

In a preferred embodiment, the power contact is comprised of a highlyconductive high-performance copper alloy material. Some high performancecopper alloy materials are highly conductivity material. One example ofa highly conductive high-performance copper alloy material is sold underthe descriptor C18080 by Olin Corporation. However, in alternateembodiments, other types of materials could be used. A highly conductivehigh-performance copper alloy material may have a minimum bend radius tomaterial thickness ratio (R/T) of greater than one; whereas commonconventional metal conductors may have a R/T of less than ½. However, ahighly conductive high performance copper alloy material may not be asmalleable as other common electrically conductive materials used forelectrical contacts. Thus, an electrical contact formed with a highlyconductive high-performance copper alloy material may be more difficultto form in conventional contact stamping and forming dies.

Referring also to FIGS. 6-9, the second power connector 24 generallycomprises a housing 74 and four electrical power contacts or terminals76, 78. The housing 74 is preferably comprised of a molded plastic orpolymer material. The housing 74 generally comprises a rear section 80and a front section 82. The rear section 80 generally comprises contactmounting areas 84 formed along air flow passages 86.

In the embodiment shown, the air flow passages 86 form a majority of across sectional size of the rear section 80. The air flow passages 86comprise holes through a top side 88 and a rear side 90 and bottom sideof the rear section 80. The bottom side of the rear section 80 includesmounting posts 92 for mounting the housing on the daughter printedcircuit board 12. In the embodiment shown, the housing 74 issubstantially the same as the housing 26 except for the shape of thecontact mounting areas 84.

The front section 82 is identical to the front section 32. However, inalternate embodiments, the front section 82 could comprise a differentshape. The front section 82 generally comprises a mating connectorreceiving area 94, air passage holes 96, 98 at top and bottom sides ofthe front section, and mating connector aligner receiving grooves 100.The mating connector receiving area 94 is sized and shaped to receive aportion of a mating connector of the mother board connection section 18.The mating connector aligner receiving grooves 100, in the embodimentshown, are located on a top side and two lateral sides of the frontsection 82. The air passage holes 96, 98 are provided to allow air toflow into and out of the mating connector receiving area 94.

As noted above, the connector 24 comprises four power contacts 76, 78.However, in alternate embodiments, the connector could comprise more orless than four power contacts. The power contacts are provided in twosets, each set comprising a second type of contact 76 and a third typeof contact 78. The two contacts in each set are aligned with each otherin a same plane as an upper contact and a lower contact.

The second and third types of power contacts 76, 78 are each preferablycomprised of a one-piece metal member which has been stamped andsubsequently plated. The power contact 76, 78 are substantially flatexcept at their mating connector contact sections. In the embodimentshown, the daughter board electrical contact sections comprise aplurality of through-hole contact tails.

As seen best in FIG. 8, each second type of power contact 78 generallycomprises a main section 102, daughter board electrical contact sections104, and mating connector contact section 106. The power contact 78comprises only one mating connector contact section 106. However, inalternate embodiments, the second type of power contact 78 couldcomprise more than one mating connector contact section.

The main section 102 comprises a retention section 118 located at abottom side of the main section. The retention sections engage with thehousing 26 to fixedly hold the main section 102 in the housing. In theembodiment shown, the contacts 78 are loaded into the housing 74 throughthe rear end of the housing.

As seen best in FIG. 9, each third type of power contact 76 generallycomprises a main section 122, daughter board electrical contact sections124, and a mating connector contact section 126. The power contact 76comprises only one mating connector contact section 126. However, inalternate embodiments, the second type of power contact 76 couldcomprise more than one mating connector contact section.

The main section 122 comprises a retention section 138 located at abottom side of the main section. The retention sections engage with thehousing 74 to fixedly hold the main section 122 in the housing. In theembodiment shown, the contacts 76 are loaded into the housing 74 throughthe front end of the housing; through the mating connector receivingarea 94.

The mating connector contact sections 106, 126 are identical to eachother and to the mating connector contact section 56. However, inalternate embodiments, the mating connector contact sections could bedifferent from each other. When the power contacts 76, 78 are insertedinto the housing 74, the mating connector contact sections 106, 126 arelocated in the mating connector receiving area 94. Each mating connectorcontact section 106, 126 generally comprises the three forwardprojecting cantilevered beams; the first beam 58 and the two secondbeams 60. However, in alternate embodiments, the mating connectorcontact section could comprise more or less than three cantileveredcontact beams.

The first beam 58 extends outward in a first direction as the first beamextends forward from the main section. The first beam 58 has a contactsurface 62 facing the first direction. The second beams 60 are locatedon opposite top and bottom sides of the first beam 58. The second beams60 extend outward in a second opposite direction as the second beamsextend forward from the main section 52. The second beams 60 havecontact surfaces 64 facing the second direction.

The beams 58, 60 are bent outward about 15 degrees from a central plainof the power contacts. However, in alternate embodiments, any suitableangle could be provided. In the embodiment shown, the front ends of thebeams 58, 60 are curved inward and also comprise coined surfaces ontheir outer contact surfaces 62, 64. The front ends of the beams 58, 60could comprise any suitable type of shape.

In a preferred embodiment, the power contacts 76, 78 are comprised of ahigh-performance copper alloy material. However, in alternateembodiments, other types of materials could be used. As noted above, ahighly conductive high performance copper alloy material can have ahigher conductivity, but might not be as malleable as other commonelectrically conductive materials used for electrical contacts. Thus, anelectrical contact formed with a highly conductive high-performancecopper alloy material might be more difficult to form in a conventionalcontact stamping and forming die. However, the shape of the matingconnector contact sections 56, 106, 126 has been specifically designedto be relatively easily formed by a stamping process even though thestock material used to form the contacts comprises a relatively lowmalleability, high conductivity high-performance copper alloy material.

A feature of the present invention is the contact geometry at the matingconnector contact sections 56, 106, 126. The contact geometry providesthe ability to raise or lower the normal force of the contact beams 58,60 on the contacts 146 by merely lengthening or shortening the length ofthe beams. The contact geometry requires only minimal forming at themating interface. This is extremely beneficial for use with relativelylow malleability materials, such as some high-performance copper alloys.

Compared to a conventional design, such as disclosed in the U.S. Pat.No. 6,319,075, the contact geometry and the minimized forming needed tobe done at the mating interface 56, 106, 126, reduces tooling costs,reduces material costs, maximizes voltage rating, and allows the housingto be designed to permit more air flow through the mated connectorsystem. The header terminal design can be adjusted to optimize thenormal force, by adjusting beam length, because of the opposing beamdesign. Two small beams 60 opposing one larger beam 58 causes the netbending moment on the housing to be minimized.

As noted above, one feature of the present invention is the increasedamperage density which can be provided by the power connectors. Forexample, the second type of connector 24 can provide for 15 amps ofcurrent per contact for a total of 60 amps per connector. The bottomside of the connector 24 can be as small as a half-inch, for example,such that the amperage density can be provided at about 60 amps per halfinch. This increased amperage density, relative to conventional designs,can be provided due to the higher conductivity of the high performancecopper alloy and, due to the increased air flow through the connectorhousings 26, 74, 144 (see FIGS. 4, 7 and 10).

Also as noted above, another feature of the present invention is theability for the power connectors to meet specification standards for agiven voltage for secondary circuit power card-to-back panel interfaces.More specifically, it has been found that implementation of the presentinvention can meet the specifications for UL 60950, IEC 61984 and IEC664-1 for a 150-160 Volt secondary circuit power card-to-back panelconnection.

The mother board connection section 18 (see FIGS. 1 and 2) generallycomprises a signal connector 140 and two power connectors 142. In theembodiment shown, the three connectors 140, 142 are shown stackedadjacent each other with the signal connector 140 located between thetwo power connectors 142.

The signal connector 140 generally comprises a header connector with ahousing with a plurality of male signal contacts and possibly groundcontacts. In a preferred embodiment, the signal connector 140 comprisesa Metral™ header connector manufactured and sold by FCI USA, Inc.

Referring also to FIGS. 10-12, the power connectors 142 each generallycomprises a housing 144 and electrical power contacts or terminals 146.The housing 142 is preferably comprised of a molded plastic or polymermaterial. The housing 142 generally comprises four receiving areas 148;one for each of the mating connector contact sections of the connector22 or 24. However, in alternate embodiments, the housing could comprisemore or less than four receiving areas. In the embodiment shown, thehousing 144 also comprises three aligners 154 located on threerespective sides of the housing and projecting from a front end of thehousing. The aligners 154 are sized and shaped to be received in thealigner receiving areas 50, 100 of the connector 22 or 24. The aligners154 function as protruding guide features to ensure that both matinghousings are properly positioned before mating begins.

Top and bottom sides of the housing 144 also comprise holes 156therethrough. When one of the connectors 22 or 24 are connected to oneof the connectors 142, the holes 156 are at least partially aligned withthe holes 46, 48, or 96, 98. This allows air to flow through the holesinto and out of the mating connector receiving area 44 and inside theconnector 142. In a preferred embodiment, the housing 144 is cored toallow for air flow through the mating connector system. The increasedair flow allows for increased heat dissipation from the power contacts28, 76, 78.

In the embodiment shown, the power connector 142 comprises eight of thepower contacts 146. However, in alternate embodiments, more or less thaneight power contacts could be provided. Each power contact 146 comprisesmother board mounting sections 150 and a main section 152. The powercontacts 146 are preferably formed from a flat stock material and, afterbeing formed, each power contact 146 comprises a general flat shape.

In the embodiment shown, two of the power contacts 146 are inserted intoeach one of the receiving areas 148. More specifically, the two powercontacts 146 are inserted adjacent opposite sides of each receiving area148. This forms an area between the two power contacts 146 in eachreceiving area 148, located between the opposing interior facing contactsurfaces of the two power contacts, which is sized and shaped to receiveone of the mating connector contact sections 56, 106 or 126.

The present invention provides an inverse connection system. When thedaughter board connection section 16 is mated with the motherboardconnection section 18, the two signal connectors 20, 140 mate with eachother and the two power connectors 22, 24 mate with respective ones ofthe power connectors 142. The mating connector contact sections 56, 106,126 project into the receiving areas 148. The contact surfaces 62 of thefirst beams 58 contact a first one of the pair of power contacts 146,and the contact surfaces 64 of the second beams 60 contact a second oneof the pair of power contacts in the same receiving area 148. The firstcontact beams 58 are deflected slightly inward and the second contactbeams 60 are also deflected slightly inward in an opposite directionrelative to the first contact beams. Thus, the mating connector contactsections 56, 106, 126 make electrical contact on two inwardly facingsides with the pairs of power contacts in the mating power connector142.

As seen in comparing the a first type of power contact 28 shown in FIG.5 to the second and third power contacts 78, 76 shown in FIGS. 8 and 9,the contacts share numerous similarities. In one type of method forforming the contacts, a same metal stamping die is used to form all ofthe contacts. The apparatus used to stamp the metal stock materialincludes an optional insert tooling punch which can be inserted into themetal stamping die. The metal stamping die can form the first type ofelectrical power contact 28 when the insert tooling punch is notinserted into the metal stamping die. However, when the insert toolingpunch is inserted into the metal stamping die, then, when the metalstock material is stamped by both the metal stamping die and the inserttooling punch, the second electrical power contact 78 and the thirdelectrical power contact 76 are substantially simultaneously formed fromthe metal stock material.

Referring to FIGS. 13A and 13B, FIG. 13A shows a perspective view of twoof the first type of contacts 28 formed from metal stock material on acarry strip 116, and FIG. 13B shows a perspective view of two pairs ofthe second and third types of contacts 76, 78 formed from metal stockmaterial on a carry strip 116 formed with a same metal stamping die asused to form the first type of contacts 28 shown in FIG. 13A and withuse of an additional, optional insert tooling punch. The insert toolingpunch removes sections 160, 161 to separate the contacts 76, 78. Thus,the metal stamping die and the optional insert tooling punch can be usedto form the three different types of electrical power contacts andsubsequently form the two different types of electrical power connectors22, 24.

Referring now to FIGS. 14 and 15, this method is illustrated. As shownin FIG. 14, the stock material is inserted 160 into the stampingapparatus. The stamping apparatus then stamps 162 the stock materialwithout the insert tooling punch inserted in the metal stamping die. Theformed first type of contact is then plated 164 and inserted 166 intothe first type of housing. This forms the first type of connector 22.

FIG. 15 illustrates the steps for forming the second type of connector24. The insert tooling punch is inserted 168 into the metal stampingdie. The stock material is inserted 170 into the stamping apparatus. Thestamping apparatus than stamps 172 the stock material with both themetal stamping die and the insert tooling punch. This forms the secondand third types of contacts 78, 76 which are subsequently plated 174.The second and third types of contacts are then inserted 176 into thesecond type of housing to form the second type of power connector 24.This method illustrates merely one form of method that can be used toform power connectors incorporating features of the present invention.In alternate embodiments, any suitable method for forming the powerconnectors as described above could be used.

The present invention could be embodied or used with other alternateembodiments than described above. For example, the daughter boardconnection section 16 could comprise more or less than the threeconnectors, and one or more of the connectors might not be stackedadjacent the other connectors. In addition, in another type of alternateembodiment, the housings for two or more of the connectors might beformed by a one-piece molded housing. The signal connector 20 couldcomprise any suitable type of signal connector. The air flow passages 36might not form a majority of a cross sectional size of the rear section30. The air flow passages 36 in the rear section 30 could also compriseany suitable size and shape. Any suitable system for loading thecontacts into the housing could be provided. The front ends of the beams58, 60 could comprise any suitable type of shape. Features of thepresent invention could be incorporated into vertical headers, rightangle receptacles, and power connectors with different contact arraysother than the 1×2 and 2×2 contact arrays described above.

It should be understood that the foregoing description is onlyillustrative of the invention. Various alternatives and modificationscan be devised by those skilled in the art without departing from theinvention. Accordingly, the present invention is intended to embrace allsuch alternatives, modifications and variances which fall within thescope of the appended claims.

What is claimed is:
 1. A printed circuit board electrical power contactfor connecting a daughter printed circuit board to a mating contact onanother electrical component, the power contact comprising: a mainsection; at least one daughter board electrical contact sectionextending from the main section; and at least one mating connectorcontact section extending from the main section, the mating connectorcontact section comprising at least two forward projecting beams,wherein a first one of the beams extends outward in a first direction asthe first beam extends forward from the main section and has a contactsurface facing the first direction, and wherein a second one of thebeams extends outward in a second opposite direction as the second beamextends forward from the main section and has a contact surface facingthe second direction, wherein the first beam is larger than the secondbeam.
 2. A system for connecting a daughter printed circuit board to amother printed circuit board, the system comprising: a first powerconnector adapted to be mounted to the mother printed circuit board, thefirst power connector having a first housing and first power contacts; asecond power connector adapted to be mounted to the daughter printedcircuit board, the second power connector having a plurality of secondpower contacts, each second power contact having a main section withoutwardly bent contact beams having outward facing contact areas, theoutwardly bent contact beams comprising a first contact beam which islarger than a second contact beam, wherein the first and second contactbeams extend in generally opposite directions from a front end of themain section, and wherein the second power contacts are adapted to beinserted into the first housing; a first signal connector adapted to bemounted to the mother printed circuit board, the first signal connectorcomprising male signal contacts; and a second signal connector adaptedto be mounted to the daughter printed circuit board, the second signalconnector comprising female signal contacts adapted to receive the malesignal contacts therein.
 3. An electrical contact comprising: a mainsection; a first electrical contact section extending from the mainsection, wherein the first electrical contact section is adapted toconnect to a first device; and a second electrical contact sectionextending from the main section, wherein the second electrical contactsection is adapted to connect to a second device, wherein the secondelectrical contact section comprises at least two beams projecting fromthe main section in a connection direction for connecting the secondelectrical contact section to the second device, wherein a first one ofthe beams extends outward in a first direction as well as in theconnection direction from the main section and has a first contactsurface facing the first direction, wherein a second one of the beamsextends outward in a second direction as well as in the connectiondirection from the main section and has a second contact surface facingthe second direction, and wherein the first beam is larger than thesecond beam.
 4. An electrical contact as in claim 3 wherein the seconddirection is generally opposite to the first direction.
 5. An electricalcontact as in claim 3 wherein the second direction is a lateraldirection relative to the connection direction.
 6. An electrical contactas in claim 5 wherein the second direction is generally opposite to thefirst direction.
 7. An electrical contact as in claim 3 wherein thesecond direction is orthogonal to the connection direction.
 8. Anelectrical contact as in claim 7 wherein the second direction isgenerally opposite to the first direction.
 9. An electrical contact asin claim 3 wherein the second electrical contact section comprises twoof the second beams.
 10. An electrical contact as in claim 9 wherein thetwo second contact beams are located on opposite sides of the firstbeam.
 11. An electrical contact as in claim 3 wherein the secondelectrical contact section comprises a pair of two of the second beamsfor each first beam, and wherein each of the second beams are located atdirectly opposite sides of their respective first beam.
 12. Anelectrical connector assembly comprising: a first electrical connectorcomprising a first housing and a first electrical contact, wherein thefirst housing comprises at least two first heat dissipation holesextending from an exterior side of the first housing to an interior ofthe first housing, where the at least two first heat dissipation holesare located on opposite sides of the first housing; a second electricalconnector comprising a second housing and a second electrical contact,wherein the second housing comprises at least two second heatdissipation holes extending from an exterior side of the second housingto an interior of the second housing, where the at least two second heatdissipation holes are located on opposite sides of the second housing;wherein the first housing comprises a receiving area adapted to receiveat least a portion of the second housing, wherein the first heatdissipation holes extend into the receiving area of the first housing,wherein a first pair of the first and second heat dissipation holes arelocated on the housings to at least partially vertically align adjacenteach other when the second electrical connector is inserted into thereceiving area of the first housing, wherein a second pair of the firstand second heat dissipation holes are located on the housings to atleast partially vertically align adjacent each other when the secondelectrical connector is inserted into the receiving area of the firsthousing, where the first pair of heat dissipation holes is alignedsubstantially unobstructed relative to the second pair of heatdissipation holes for air to flow from the receiving area of the firsthousing out of the electrical connector assembly.
 13. An electricalconnector assembly as in claim 12 wherein the first housing comprisestwo of the first heat dissipation holes located at the two oppositesides of the first housing.
 14. An electrical connector assembly as inclaim 13 wherein the second housing comprises two of the second heatdissipation holes located at the two opposite sides of the secondhousing.
 15. An electrical connector assembly as in claim 12 wherein theopposite sides of the first housing comprise a top side and a bottomside of the first housing.
 16. An electrical connector assemblycomprising: a first electrical connector comprising a first housing anda first electrical contact, wherein the first housing comprises a firstheat dissipation hole extending from an exterior side of the firsthousing to an interior of the first housing; a second electricalconnector comprising a second housing and a second electrical contact,wherein the second housing comprises a second heat dissipation holeextending from an exterior side of the second housing to an interior ofthe second housing; wherein the first housing comprises a receiving areaadapted to receive at least a portion of the second housing, wherein thefirst heat dissipation hole extends into the receiving area of the firsthousing, wherein the first and second heat dissipation holes are locatedon the housings to at least partially vertically align adjacent eachother when the second electrical connector is inserted into thereceiving area of the first housing where the first and second heatdissipation holes are aligned substantially unobstructed for air to flowfrom the receiving area of the first housing out of the electricalconnector assembly, wherein the first electrical contact comprising: amain section; at least one daughter board electrical contact sectionextending from the main section; and at least one mating connectorcontact section extending from the main section, the mating connectorcontact section comprising at least two forward protecting beams,wherein a first one of the beams extends outward in a first direction asthe first beam extends forward from the main section and has a contactsurface facing the first direction and wherein a second one of the beamsextends outward in a second opposite direction as the second beamextends forward from the main section and has a contact surface facingthe second direction, wherein the first beam is larger than the secondbeam.
 17. An electrical connector comprising: an electrical contact,wherein the electrical contact comprises; a main section; at least onedaughter board electrical contact section extending from the mainsection; and at least one mating connector contact section extendingfrom the main section, the mating connector contact section comprisingat least two forward projecting beams, wherein a first one of the beamsextends outward in a first direction as the first beam extends forwardfrom the main section and has a contact surface facing the firstdirection, and wherein a second one of the beams extends outward in asecond opposite direction as the second beam extends forward from themain section and has a contact surface facing the second direction,wherein the first beam is larger than the second beam; a housing havingthe electrical contact mounted to the housing, wherein the housingcomprises a receiving area adapted to receive a portion of a matingelectrical connector, wherein the electrical contact extends into thereceiving area, wherein the housing comprises heat dissipation holesextending from an exterior side of the housing through different wallsof the housing and into the receiving area, wherein the housing is sizedand shaped, and the heat dissipation holes are located at predeterminedlocations on the housing such that at least some of the heat dissipationholes are aligned relative to each other on opposite sides of thehousing, and where the heat dissipation holes are located at thepredetermined locations on the housings to at least partially verticallyalign the heat dissipation holes with heat dissipation holes of a matingelectrical connector when the mating electrical connector is connectedto the electrical connector for the heat dissipation holes to besubstantially unobstructed for air to flow from the receiving area ofthe first housing out of the electrical connector assembly through thealigned heat dissipation holes.
 18. An electrical connector as in claim17 wherein the different walls of the housing comprise a top side of thehousing and an opposite bottom side of the housing.
 19. A methodcomprising: connecting a first electrical connector to a secondelectrical connector, wherein the first and second electrical connectorseach comprise a housing having an interior open space with matingportions of electrical contacts in the open spaces; and when the firstand second electrical connectors are being connected to each other, atleast partially vertically aligning first heat dissipation holes on thehousing of the first electrical connector with second heat dissipationholes of the housing of the second electrical connector as aligned pairsof holes, wherein the heat dissipation holes extend through the housingsbetween exterior sides of the housings and interior open spaces suchthat heated air can flow from the interior open spaces out of thehousings through the aligned pairs of holes, where a first pair of thefirst and second heat dissipation holes and a second pair of the heatdissipation holes on opposite sides of the housings are alignedsubstantially unobstructed for the air to flow through the aligned pairsof heat dissipation holes when the electrical connectors are connected.20. A method as in claim 19 wherein the housing of the first electricalconnector comprises two of the first heat dissipation holes and thehousing of the second electrical connector comprises two of the secondheat dissipation holes, wherein the pairs of heat dissipation holes arelocated on opposite sides of the electrical connectors when theelectrical connectors are connected to each other.
 21. A method as inclaim 19 wherein the opposite sides of the housings comprise oppositetop and bottom sides of the housings.